Apparatus for removing sulfur from sulfur containing gases

ABSTRACT

Apparatus for treating acid gas-containing flue gases to remove acid gases therefrom. Apparatus in accordance with the present invention include a device for heating an admixture of calcium alkali and calcium-reactive silica and/or alumina to above ambient temperatures for a period of time so as to facilitate the formation of acid gas-absorbing calcium silicates or aluminates. These apparatus further include a chamber for receiving activated absorbing components from the heater chamber wherein the activated absorbing component is admixed with gas to allow absorption of acid components therefrom. After absorption of acid components from the gas, the apparatus separates the treated gas from the spent absorbing component. Examples disclosed herein demonstrate the utility of these apparatus in achieving improved sulphur-absorbing capabilities. Additionally, disclosure is provided which illustrates preferred configurations for use in connection with coal-fired generating plants.

gas and thereby achieve both humidification and reduction in the temperature of the hot flue gas. The admixing means will generally be in the form of a dry sorbent injector system as is commonly known in the art. The separating means (for example, a baghouse or electrostatic precipitator) can be employed as in the general embodiment.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1. Schematic Diagram of a Spray Dryer System.

FIG. 2. Experimental apparatus.

FIG. 3. The effect of fly ash I, II, III, and IV and relative humidity on Ca(OH)₂ utilization. 0.4 g of Ca(OH)₂ slurried with 1.6 g of fly ash I for 4 hours at 65° C. Atmospheric drying used for the preparation of samples. L=Ca(OH)₂ alone.

FIG. 4. The effect of fly ash I loading (g fly ash/g Ca(OH)₂) on lime utilization. Samples slurried for4 hours at 65° C. Atmospheric drying.

FIG. 5. A fly ash simulation experiment carried out at 54% RH. Samples of simulated fly ash (Av.Fa), H₂ SiO₃, Al₂ O₃, and Fe₂ O₃ slurred with Ca(OH)₂ for 4 hours at 65° C. Atmospheric drying.

FIG. 6. The effect of silica (H₂ SiO₃, Zeothix 265, or Zeofree 80) loading (g silica/g Ca(OH)₂) on time utilization. Atmospheric drying.

FIG. 7. The effect of alumina loading (g alumina/g Ca(OH)₂) on lime utilization. Atmospheric drying.

FIG. 8. The effect of fly ash IV on Ca(OH)₂ reactivity. Fly ash IV loading 16. Vacuum drying.

FIG. 9. Effect of NaOH concentration on SO₂ removal. 1 Ca(OH)₂ :4 Fly Ash:4 CaSO₃ --10 mol % NaOH; Removal after 1 hour; 500 ppm SO₂ ; 500 ppm NO_(x) ; 14 mol % H₂ O; gas flow: 4.6 1/min - 7% O₂, 10% CO₂ ; 83% N₂.

FIG. 10. Generalized process schematic for high temperature sorbent preparation and use.

FIG. 11. Effects of pressure hydration on the reactivity of calcium silicate hydrates prepared at the weight ratio of fly ash to lime of 3:1.

FIG. 12. The effect of temperature of pressure hydration on the reactivity of calcium silicate hydrates prepared at the weight ratio fly ash to lime of 3:1.

FIG. 13. Correlation between measured B.E.T. surface area and the reactivity of various calcium silicate hydrates prepared from fly ash and lime.

FIG. 14. Correlation between temperature of sorbent preparation and incubation time required to obtain a doubling of sorbent reactivity.

DETAILED DESCRIPTION OF THE INVENTION The CaO--SiO--Al₂ O₃ --H₂ O Sulfur Absorption System

The nature of calcium silicate hydrate and calcium aluminate hydrate as well as calcium aluminate silicate hydrate formation in CaO--SiO₂ --Al₂ O₃ --H₂ O systems is very complicated. It is usually impossible to assign a simple chemical formula to it, especially at ordinary temperatures of interest in flue gas desulfurization. At temperatures from 20° C. to about 100° C., two main calcium silicate hydrates are formed, mono- and dicalcium silicate hydrates. Their ratio appears to depend on the initial ratio of calcium to silica in the slurry. Both monocalcium silicate hydrate--CaOxSiO-- and dicalcium silicate hydrate--(CaO)₂ xSiO₂ xH₂ O--are fibrous gels of specific surface areas in the range of 100-300 m² /g. At 20°-100° C. after 8 hours of hydration, tobermorites (calcium silicate hydrates) may crystallize, also of high surface area.

The reaction of fly ash and Ca(OH)₂ in the presence of water is called a pozzolanic reaction. A pozzolan is a siliceous or siliceous and aluminous material which in itself possesses little or no cementitous value but will, in finely divided form and in the presence of moisture, chemically react with calcium hydroxide at ordinary temperatures to form compounds possessing cementitous properties. Due to small particle size and generally noncrystalline character, fly ash usually shows pozzolanic properties, or pozzolanic and cementitous properties in case of high-calcium ashes. High-calcium fly ash contains tricalcium aluminate hydrate, which is the most reactive mineral present within portland cement. Pozzolanic reactions give products with cementitous properties and with high surface area that can enhance SO₂ removal.

Pozzolan originated as a mortar of lime and ash (from Pozzouli, Italy) which the Romans used for stone constructions. The definition of pozzolanic reaction implies that spray dryer off-products, fly ashes, clays, and sands should be able to provide components to form calcium silicate hydrates, calcium aluminate hydrates,calcium alumino-ferrite hydrates, calcium sulfo-aluminate hydrates (ettringites), and calcium sulfo-aluminate-ferrite hydrates. However, not all siliceous and aluminous minerals are pozzolans. Crystalline minerals (mullite, silica as quartz) do not react with lime, especially at ordinary temperatures. Siliceous and/or aluminous materials must be non-crystalline and in small particles, in order to provide silica and alumina, after hydration in alkaline solutions, to form cementitous products. These reactions are the ones which constituents of portland cement undergo in the presence of water. The hydration reaction of aluminates in the presence of gypsum and lime and reaction of calcium silicates are as follows: ##STR1##

Typical portland cement consists of 50% tricalcium silicate, 25% dicalcium silicate, 10% tricalcium aluminate, 9% calcium alumino-ferrite, and 6% calcium sulfate. Tricalcium silicate appears to be the most reactive mineral present within the portland cement. The main product of hydration of portland cement's silicate materials is calcium silicate hydrate of colloidal dimensions. All calcium silicate hydrates are fibrous gels in early stage of formation and their surface area is in the range of 100-300 m² /g. Moreover, Tobermorite gel plays a vital role in establishing the strength of concrete.

When considering the spray dryer/bag filter system, typically one is dealing with fly ash as a source of silica instead of amorphous silica. The solubility of quartz particles of 3-15 um diameter in water is 11 ppm at 25° C. and 60 ppm at 100° C. The corresponding values for amorphous silica are 130 ppm and 420 ppm, respectively. Temperature and pH have strong effects on the solubility of amorphous silica. When pH was adjusted with NaOH up to 10.5 from 7 at 25° C., solubility was found to increase to 1000 ppm. Above a pH of 10.7, all the solid phase of amorphous silica dissolves to form soluble silicate. Therefore it would be reasonable to expect the dissolution of fly ash to be the limiting step in the formation of calcium silicate hydrates. Because of the lower solubility of fly ash, the specific surface area of the Ca(OH)₂ /silica reaction product is smaller than values reported for laboratory studies with amorphous silica. Also, it is not clear whether the development of the specific surface area of the product of hydration (for a given ratio of Ca(OH)₂ /fly ash) increases proportionally to the amount of conditioned lime.

Because of low fly ash reactivity it is often desirable to know the exact characteristics of fly ash to b used. Usually fly ashes are divided into two categories: low-calcium (containing less than 5% of analytical CaO) from burning bituminous or anthracite coals and high-calcium (up to 35% Ca) from burning lignite or subbituminous coals. However, from the point of perspective reactivity and formation of calcium silicate hydrates, it is generally more important how much more amorphous material there is within the fly ash as compared with crystalline substances. Higher contents of crystalline phases (alpha-quartz, mullite, sillimanite, hematite, magnetite) lowers the reactivity of fly ash. Low-calcium fly ashes consist mainly of aluminosilicate glass due to the high proportions of silica and alumina. However, some crystallization takes place in the boiler when fly ash is cooling and, as a result, crystalline phases are detected under glass.

For high-calcium fly ash it appears that the glass structure is different. It has been postulated that it is composed of significant amounts of CaO & Al₂ O₃, which is known to be highly reactive. Since the non-crystalline component comprises sometimes as much as 80% of high-calcium fly ash it seems that the reason for high reactivity of high-calcium fly ash may be in the composition of glass. On the other hand, higher contents of unburnt carbon in the low-calcium fly ash may add to its reactivity. These carbon particles are usually of high internal surface area and may bind water and admixtures when the fly ash is slurried.

In a study of surface area and porosity of fractionated fly ash from burning low-sulfur, high-ash coal, the largest fraction (>125 um) had a surface area of 9.44 m² /g the finest fraction (>7 um) had a surface area of 1.27² /g. Since large particles constitute a small fraction of fly ash only, the above effect is relatively insignificant. Industrial experiments should outperform laboratory tests, since it has been found that high-calcium fly ash passed the lime pozzolanic activity test when

20 commercial source of lime was used, but failed to do so in the presence of a reagent grade Ca(OH)₂. This effect is possibly the result of impurities in lime which have formed poorly-crystallized hydrates.

The prospect of having calcium silicate hydrates in the spray dryer/bag filter therefore appears to be very attractive since they have high surface area and are highly hydrated and therefore should offer high SO₂ removal potential. The formation would take place in the recycle system, specifically in the reactant tank. During fly ash recycle in dry flue gas desulfurization systems, reaction of fly ash with makeup Ca(OH)₂ probably takes place in several steps. First lime would be dissolved, then silica and alumina--originally contained within the fly ash--would be digested and, by the means of providing favorable slurrying conditions, calcium silicate/aluminate hydrates would be formed.

System Overview

Referring to FIG. 1 is seen a diagram of a typical spray dryer system which is particularly well suited to the practice of the processes of the present invention. Depicted therein is a spray dryer 1, a baghouse 3, and a slurry tank 5. The slurry tank 5 is adapted to receive calcium alkali, in the form of, for example, lime from storage by means of conduit 7, and water by means of conduit 9. The slurry tank further includes a heating element 11 adapted to heat the slurry for times and to temperatures in accordance with processes of the present invention. The system may be adapted to provide calcium reactive alumina or silica directly to the slurry from storage by means of conduit 13 or, alternatively, calcium reactive silica or alumina is supplied to the slurry tank 5 by means of a recycle conduit 15 containing a sulfur-absorbed solids recycle, which includes, for example, fly ash from the boiler.

To obtain best results, the slurry tank 5 is designed to mix a mass ratio of water to solids ranging from 1:1 to 20:1. Moreover, the slurry tank 5 and heating element 11, are adapted so as to enable a heating of the slurry to a temperature ranging from about 40° C. to about 140° C. for between about 0.5 to about 48 hours.

The heat-treated slurry is conveyed to the spray dryer 1 by means of conduit 17. In the spray dryer 1, the slurry is admixed with flue gas from the boiler by means of a rotary atomizer 19. The gas/slurry mixture is partially dried in the spray dryer 1 which is typically designed to achieve a gas/slurry contact time of between about 2 and about 10 seconds. In addition, a partial absorption of sulfur by the slurry is achieved in the spray dryer 1.

From the spray dryer 1, the partially dried particles sulfur-absorbed gas/slurry admixture is conveyed to the baghouse 3 by means of conduit 21, wherein further drying and further absorption of sulfur by the sulfur-adsorbing component of the slurry takes place. Within the baghouse 3, the gas/slurry mixture is directed onto a bagfilter 23 wherein sulfur-absorbed solids are deposited and further absorption and drying takes place. The bagfilter 23 thus serves a dual purpose of separating gas from dried solids and collecting the solids for disposal by means of conduits 25, or recycle of solids by means of conduit 15. Separated gases are vented by means of conduit 29. Solids collected in the spray dryer are mixed with baghouse solids by means of conduit 27. Typically, the baghouse 3 and bagfilter 23 are designed to achieve a residence time of between about 5 and 300 minutes.

In system embodiments for use in conjunction with dry injection of solids, the system will typically include a humidifier 29 in place of the spray dryer 1, wherein hot flue gas is admixed with water to provide humidified, cooled gas. Moreover, the system would also further include a drying tank 31 wherein the slurry is dried prior to admixture of the dried slurry with the humidified gas. Additionally, the dry injection system may include a recycle conduit 33 for admixture of recycled solids with the slurry mixture in the drying tank 31, to further assist in drying the slurry mixture. Alternatively, the spray dryer 1 itself can serve as a combination humidifier and injector wherein the dried slurry is injected into the spray dryer 1 along with water to provide admixture of the dried slurry together with the water and the gas.

EXAMPLE I: LAB SCALE EXPERIMENTS Apparatus

Experiments were conducted in the apparatus shown in FIG. 2. The glass reactor (40 mm in diameter, 120 mm in height) was packed with a powdered reagent mixed with 40 g of 100 mesh silica sand to prevent channelling of Ca(OH)₂. The reactor was immersed in a water bath thermostated to within approximately 0.1° C. Simulated flue gas was obtained by mixing nitrogen and sulfur dioxide from gas cylinders. The flow of gas was monitored using rotameters. Water was metered by a syringe pump, evaporated, and injected into dry gas. Reactor upstream tubing was heated to prevent the condensation of the moisture.

Before entering the analyzer, the gas was cooled and water condensed in an ice bath. The SO₂ concentration was measured with a pulsed fluorescent SO₂ analyzer (Thermo-Electron Model 40). A bypass of the reactor was provided to allow preconditioning of the bed and stabilization of gas flow at the desired SO₂ concentration. Prior to each run the bed was humidified by passing pure nitrogen at a relative humidity of about 98% for 6 minutes and then pure nitrogen at a relative humidity at which the experiment was to be performed for 10 minutes.

Most of the experiments were performed at a relative humidity of 54% with some experiments at 17% and 74%. At typical flue gas conditions, 17, 54, and 74% relative humidity corresponds to 38, 9.5, and 4.7° C. approach to saturation, respectively. Reactor temperature was 95, 66, and 64.4° C. for 17, 54, 74% relative humidity, respectively. Common purity (99.5%) nitrogen at 4.6 1/min (0° C., 1 atm) was used as a carrier gas. The nominal concentration of SO₂ was 500 ppm and exposure time of the sample to the sulfurized gas was 1 hour.

Preparation of the Samples

The sample preparation consisted of two essential steps: stirring and drying. In every experiment 0.4 of reagent grade Ca(OH)₂ was used. This amount of lime was slurried with fly ash or other additive at the desired weight ratio. The water to solids ratio was between 10:1 and 20:1--most often 15:1. A propeller stirrer at 350 rpm was used to agitate the slurry. Slurrying time varied from 2 to 24 hours and the temperature of the slurry was set at 25 to 92° C.

Two different methods of sample preparation was used during this study. In atmospheric drying, samples were not filtered after slurrying and were dried overnight in an atmospheric over at 85°-90° C. It took several hours to evaporate the water. The new drying procedure--vacuum drying--was introduced to minimize the additional reaction time of a wet sample in high oven temperature (85°-90° C.). In this method the samples were vacuum filtered (about 5 min) and subsequently vacuum dried (about 10 min) at 95° C. The time of vacuum filtering and drying depended on the fineness of the sample and was monitored by the thermocouple placed in the dried sample and connected to the temperature recorder. In this way the moment when all the free moisture was evaporated could be easily seen and vacuum drying stopped, therefore minimizing the residence time of the sample in the oven.

Characterization of the Samples

Four different fly ashes were slurried with Ca(OH)₂. The characterization of fly ashes is given in Table I. During the experiments on slurrying conditions, a new batch of fly ash IV was used. It was obtained from the same vendor and was produced by burning coal from, reportedly, the same source. These samples were characterized by scanning electron microscopy (SEM). The composition of the particles has been found using Kevex Micro-X 7000 X-ray Energy Spectrometer (XES). Mean particle size

                  TABLE I                                                          ______________________________________                                         Fly Ash Characterization                                                       Fly Ash  I         II        III     IV                                        ______________________________________                                         Power Plant                                                                             Bull Run  Gibson    Seminole                                                                               San Miguel                                         Plant TVA Plant Pub-                                                                               Electric                                                                               Electric                                                     lic Service                                                                              Coop.   Coop. San                                                    of Indiana                                                                               Palatka, Fl                                                                            Miguel, TX                                Coal Type                                                                               bituminous                                                                               bituminous                                                                               bituminous                                                                             lignite                                   XES Analysis                                                                   [weight %]                                                                     CA       34         5         4      .sup. 11.sup.1                                                                      .sup. 15.sup.2                       Si       42        41        59      66   68                                   Fe        6        31        15       4    2                                   Al       16        20        20      18   14                                   Mass Median                                                                             19         9        14      10   10                                   Particle Size                                                                  [um]                                                                           ______________________________________                                          .sup.1 Old Batch                                                               .sup.2 New Batch                                                         

The Effect of Fly Ash Type and Ratio

Four samples of fly ash were slurried with 0.4 g of lime at a fly ash loading of 4 (4 g fly ash/g Ca(OH)₂) for 4 hours at 65° C. and reacted at a relative humidity of 54% (RH 54%). Atmospheric drying was used for the preparation of samples. The samples having the best and the worst performance at RH 54% were also tested at the extreme humidities of 17% and 74%. The results of these experiments are presented in FIG. 3. Also shown in FIG. 3 are the conversions when lime only was exposed to the sulfurized gas. As can be seen, all fly ashes improved the utilization at every RH investigated. Samples with fly ash loading of 16 (slurried at the sam conditions as above) enhanced utilization of RH 54% to a greater extent than was the case for fly ash loading of 4. The utilization of lime was 67, 79, 65, 71% when fly ash I, II, III, IV was used, respectively. These values were much higher than the ones presented in FIG. 3. Based on these two series of experiments no correlation was found between SO₂ removed and calcium content of fly ash sample. SEM photographs of the mixtures of Ca(OH)₂ with fly ash II, III, and IV at fly ash loading of 4 demonstrated a highly irregular deposit covering the spherules of fly ash in every picture.

Fly ash I was selected to test the effect of fly ash loading on the utilization of lime. The results of experiments at RH 54% are presented in FIG. 4. The conversion of Ca(OH)₂ increased with increasing loading of fly ash. The increase of fly ash loading from 0.5 to 20 increased the Ca(OH)₂ utilization from 17 to 78%. An SEM photograph of fly ash I slurried with Ca(OH)₂ at the low loading of 0.5 demonstrated that the deposit is very slight and unreacted chunks of Ca(OH)₂ were seen next to fly ash particles.

The Effect of Reagent Grade Additives

The other main components of fly ash were also investigated. Reagent grade Al₂ O₃, Fe₂ O₃, and H₂ SiO₃ (silicic acid) were used as a source of alumina, iron, and silica, respectively. Fly ash was simulated as a mixture of three substances: 49% H₂ SiO₃, 29% and 22% Fe₂ O₃ (weight %). Atmospheric drying was used for the preparation of samples. The results are presented in FIG. 5, giving the conversion of Ca(OH)₂ at RH 54%. During these experiments Ca(OH)₂ was slurried with additives for 4 hours at 65° C. As can be seen from FIG. 5, 1.6 g of mixture slurried with 0.4 g of Ca(OH)₂ modelled closely the utilization when fly ash I was used (30 and 27%, respectively). This again implies that calcium content of fly ash is not of primary importance, since the utilization of added Ca(OH)₂ was even higher when no fly ash-bound calcium was present. Next 0.4 g of Ca(OH)₂ was slurried separately with each component used to simulate the fly ash. Component loading was kept the same as it was when 1.6 g of mixture was used (i.e., 0.78 g, 0.47 g, and 0.35 g of H₂ SiO₃, Al₂ O₃, Fe₂ O₃ were used, respectively).

The addition of silicic acid had the most significant effect, increasing Ca(OH)₂ utilization from 12 to 40%. No SO₂ removal was observed when silicic acid alone was exposed to simulated flue gas. FIG. 6 gives the effect of silica loading on conversion at RH 17 and 54%. Silicic acid was used for most of these experiments. SEM photographs were taken of samples of silicic acid/Ca(OH)₂ slurried at 65° C. for 4 hours at silicic acid loading of 4 and 10, respectively. In both, highly developed surface of irregularly shaped particles were seen. Some experiments were performed with artificial precipitated silicas of extremely high surface areas. They were Zeothix 265 and Zeofree 80 of surface area 250 and 140 m² /g, respectively (samples and surface area data obtained courtesy of Huber Corp.). However, these substances did not enhance Ca(OH)₂ utilization significantly better than silicic acid (FIG. 6). As can be seen from FIG. 6, both values of RH tested, Ca(OH)₂ utilization increased with the increasing loading of silicic acid. The comparison of the results presented in FIGS. 4 and 6 shows that silicic acid promotes Ca(OH)₂ utilization better than fly ash. For example, at RH 54% and fly ash loading of 8 (total fly ash) the conversion of Ca(OH)₂ was 78% when silicic acid was used and 61% when fly ash I was used.

Reactivities of fly ash and silicic acid should be compared on the basis of silica content. Assuming that fly ash I is 50% silica, a silicic acid loading of 8 should be compared to fly ash I loading of 16 (conversions of 78 and 68%). The difference between silicic acid and fly ash is more apparent at lower loadings. For silicic acid loading of 1, conversion was 53% and for the fly ash I loading of 2 it was 32%. This comparison shows that Ca(OH)₂ conversion depends on the reactivity of siliceous material used.

Experiments were performed at RH of 54% with precipitated calcium silicate XP-974 (also from Huber Corp., surface area of 215 m² /g, average particle size 6.1 um). The sample was taken "as received" and was not slurried. As SEM photograph of this sample showed the particle of calcium silicate as having an irregular surface area similar to that produced when silicic acid and Ca(OH)₂ were slurried.

The effect of alumina loading was tested using two sources of alumina. The results of experiments at 54% RH are shown in FIG. 7. As can be seen, when reagent grade Al₂ O₃ was used, increasing the loading did not change SO₂ removal. No SO₂ removal was observed for Al₂ O₃ alone. The removal increased with increasing loading of alumina when activated alumina of chromatographic grade (80-200 mesh) was used. However, activated alumina alone removed SO₂. The adsorptive capacity of activated alumina was calculated as 0.023 g of SO₂ per gram. Based on this value, the corrected SO₂ removal has been determined due to the possible formation of calcium aluminates. The empty points in FIG. 7 (o) represent the overall removal of SO₂ while the filled points (o) show the corrected values. These corrected values are lower than the ones observed for the same loading when silicic acid was used instead of alumina. Therefore, the silica content of fly ash is mainly responsible for the enhancement of Ca(OH)₂ utilization.

The Effect of Slurrying Conditions

Slurrying tests were performed at 25, 45, 55, 64, and 92° C. and time was varied from 2 to 24 hours. The samples for these tests were prepared by vacuum filtration and vacuum drying. Both old and new batches of fly ash IV were used as a source of silica at 16 g fly ash/g Ca(OH)₂. Relative humidity during exposure was 54%. The results are presented in FIG. 8.

As can be seen, the temperature was the decisive parameter affecting the process. The results show that there is a critical slurrying time for every temperature tested after which Ca(OH)₂ conversion reaches a maximum value. Ca(OH)₂ conversion converged on 40% after 16 hours of slurrying at 25° C. and 80% after 5 hours at 92° C. It took 15 hours to converge on 80% conversion of Ca(OH)₂ when slurrying at 65° C. Compared with 12% utilization of Ca(OH)₂ alone at 54% RH, the 80% utilization of fly ash/Ca(OH)₂ slurried at 65° C. was dramatically improved.

The maximum utilization of Ca(OH)₂ is not a uniform function of slurry temperature (40, 50, 55, 80, and 80%, for 25, 45, 55, 65, and 92° C., respectively). There appeared to be a discontinuity between 55 and 65° C. slurrying temperature that may indicate a change in the hydration state of the calcium aluminum silicate. The resulting solid had better reactivity for SO₂ removal than that formed below 65° C. When tested by Differential Scanning Calorimeter (DSC) the solids formed at 65° C. and 92° C. have an additional endothermic peak between 416 and 465K. No peak was observed for samples slurried at 25, 45 and 55° C. The effect of a step change in reactivity also took place when fly ash III was slurried with Ca(OH)₂ at the fly ash loading of 16:1 at 65 and 45° C. The conversion of Ca(OH)₂ was 63 and 43%, respectively.

SEM photographs were taken to document the development of the surface area of the samples. In samples slurried for "0" time, separate fly ash spheres with smooth surfaces (as in an unslurried fly ash) and irregular particles of lime were seen. After 24 hours of slurrying at 25° C., the particles were covered with tiny deposits. The product on the surface of the fly ash became more densely precipitated after 24 hours of slurrying at 65° C. Increasing the temperature of slurrying to 92° C. resulted in a very well developed surface area of the deposit.

The Effect of Calcium Sulfite/Sulfate

Calcium sulfite or calcium sulfate were slurried with Ca(OH)₂ to simulate the recycle of spent lime. Laboratory produced calcium sulfite hemihydrate (90% CaSO₃ 12H₂ O+10% CaSO₄) and reagent grade calcium sulfate dihydrate were used in these experiments. Vacuum drying was used for the preparation of the samples. Samples of fly ash IV/Ca(OH)₂ /CaSO₃ at a weight ratio of 16:1:4 were slurried for 6 hours at 25, 45, and 65° C. The resulting conversions of Ca(OH)₂ were 41, 61, and 74%, respectively. Conversion of the fly ash/Ca(OH)₂ /CaSO₃ sample at a weight ratio of 16:1:4 slurried for 6 hours at 65° C. was higher than conversion of the corresponding fly ash/Ca(OH)₂ sample at a weight ratio of 20:1, which was 70%. Samples at a weight ratio of 16:1:1 were slurried for 6 hours at 25 and 65° C. and yielded Ca(OH)₂ conversions of 21 and 61%, respectively. SEM photographs of the fly ash IV/Ca(OH)₂ /CaSO₃ samples at weight ratios of 16:1:4 and 16:1:1 demonstrated long crystals that may be calcium aluminate sulfate hydrates (ettringite) of general formula 3CaO Al₂ O₃ 3CaSO₄ xH₂ O (x is most often within the range 30-32). These long crystals were not formed when only calcium sulfite was slurried with Ca(OH)₂ for 6 hours at 65° C. and at the weight ratio of 4:1 (Ca(OH)₂ conversion was 16%). Separate clusters of calcium sulfite and Ca(OH)₂ were visible by SEM. It may be that the formation of ettringite provides additional potential for SO₂ removal.

Two ratios of fly ash/Ca(OH)₂ /calcium sulfate were tried. At a ratio of 16:1:4, Ca(OH)₂ conversion was 60% for samples slurried for 6 hours at both 25 and 65° C. At a lower ratio of 16:1:1, the conversion was 51 and 31% for samples slurried for 6 hours at 65 and 25° C., respectively. SEM photographs of the sample at a weight ratio of 16:1:4 slurried for 6 hours at 65° C. revealed fly ash speres with the precipitate on the surface, as well as calcium sulfate and long crystals (ettringite).

Both calcium sulfite and calcium sulfate improved the utilization of Ca(OH)₂ after slurrying the samples for 6 hours at 25° C. and a weight ratio of 16:1:4. However, at a fly ash/Ca(OH)₂ /CaSO₃ ratio of 16:1:1, the conversion for samples slurried for 6 hours at 25 and 65° C. was lower than when fly ash was slurried at the same conditions with Ca(OH)₂ alone (21, 61, and 67%, respectively).

The Effect of Fly Ash Particle Size

Fly ash IV was wet-sieved into five fractions which are characterized in Table II. The fractionated fly ash was slurried with 0.4 g of Ca(OH)₂ at a loading of 16 for 6 hours at 65° C. Vacuum drying was used for the preparation of samples. The results of these experiments are shown in Table II. Also shown in Table II is the base case conversion of Ca(OH)₂ when it was slurried with fly ash IV ("natural"-whole spectrum of particle size). Calculated weighted average from obtained fractional conversions was 52%. The reason why the weighted average is lower than the base case (52 and 67%, respectively) may be that imperfect wet-sieving left fine particles agglomerated with coarse fractions. The general trend was that for the same fly ash loading, the conversion increased with the decreasing particle size of fly ash. An increase of the fly ash loading from 156 to 30 when the finest fraction of fly ash was used (d<20 um) resulted in an increase of Ca(OH)₂ conversion from 76 to 92%. An increase of fly ash loading from 16 to 25 when coarser fraction was used (45 um<d<75 um) resulted in an increase of Ca(OH)₂ conversion from 42 to 52%.

                  TABLE II                                                         ______________________________________                                         Fractional Characterization of Fly Ash IV                                      Fraction                                                                              Particle Diameter                                                                           Weight     Composition.sub.1                               Ca(OH).sub.2                                                                          [um]         Fraction [%]                                                                              Ca  Si  Conversion                              ______________________________________                                         1      d ≦ 1251                                                                             15         12  63  24                                      2      75 < d ≦ 125                                                                         13          8  55  28                                      3      45 < d ≦ 75                                                                          20          9  60  43                                      4      20 < d ≦ 45                                                                          12         14  67  50                                      5      d ≦ 20                                                                               .sup. 40.sup.2                                                                            14  63  77                                      6       0 < d ≦ 125+                                                                        100        15  68  67                                      ______________________________________                                          .sup.1 weight percent, normalized Energy Dispersion Spectrometry results.      .sup.2 All losses during wetsieving assumed for the finest fraction.     

Alternate Sources of Silica

Several alternative sources of silica were tested. These included siliceous clays (kaolinite and bentonite) and talc (MgO 4SiOSO₂ H₂ O). Kaolinite of the molecular composition Al₂ O₃ 2SiO₂ 2H₂ O is the principal constituent of kaolin and the most frequently occurring component of clays. Bentonite (montmorillonite clay) of general formula Al₂ O₃ 4SiO H₂ O exists as very fine particles (up to 60% below 0.1 um), which form colloidal solutions with water. Montmorillonite No. 24 (Ward's Classification) was tested. All samples were slurried for 6 hours at 65° C. at clay loading of 2. Montmorillonite was also tested at loading of 16. The coversions of Ca(OH)₂ Were 39, 25, and 23% for montmorillonite, kaolinite, and talc, respectively (at loading of 2). At similar slurrying conditions and loading of 2, fly ash I promoted Ca(OH)₂ utilization to 28% (fly ash I slurried at 65° C. for 4 hours only). At montmorillonite loading of 16, it increased the conversion to 61%, which was slightly less than fly ash I and fly ash IV. An SEM photograph was taken of the sample of montmorillonite clay No. 24 slurried with reagent grade Ca(OH)₂ at loading of 16 for 6 hours at 65° C. The highly irregular particle surface which was observed was reminiscent of the appearance of silicic acid/Ca(OH)₂ samples and of the deposit on the surface of the fly ash spheres.

In conclusion, enhanced performance of spray dryer/bag filter systems with recycle of fly ash an calcium solids is probably due to the reaction of Ca(OH)₂ with fly ash to produce calcium silicates. The calcium silicate solids were found to have greater surface area than the unreacted Ca(OH)₂ and are more effective for gas/solid reactions. Moreover, calcium silicates were found to be more reactive than aluminates or ferrites. The available silica content of the fly ash is more important. Increased time and temperature gave more reactive solids from the reaction of lime and fly ash and solids formed above 65° were substantially more reactive than solids formed at lower temperatures.

Experiments with silicic acid and fly ash support the hypothesis that the reaction of added Ca(OH)₂ and silica from fly ash is responsible for the enhancement of Ca(OH)₂ utilization when slurried with fly ash, as compared with the utilization of lime alone. The newly formed solids are of high surface area and are highly hydrated. Prior to the formation of highly reactive solids of calcium silicate hydrates two steps apparently need to take place: Ca(OH)₂ dissolution and digestion of silica from the fly ash. Since Ca(OH)₂ dissolution is very fast compared with fly ash dissolution, digestion of silica from fly ash seems to be the rate controlling step. This was confirmed by experiments with silicic acid, precipitated silica, and precipitated calcium silicate. However, the high price of precipitated silica ($750-1750/ton) make it noneconomic. Therefore enhanced calcium silicate hydrate formation should be sought by carefully selecting slurrying conditions rather than using costly additives.

Experiments showed that increasing slurrying time and temperature can dramatically enhance the utilization of Ca(OH)₂. At each temperature the Ca(OH)₂ utilization asymptoted to a specific maximum value with increasing time. The time needed to achieve the maximum utilization varied and was generally higher for lower slurrying temperatures. A step increase of reactivity was observed between solids slurried at 55 and 65° C. It took 15 hours to converge on 80% conversion of Ca(OH)₂ at 65° C.

When lime was slurried with fly ash and calcium sulfite or calcium sulfate the formation of ettringite was observed. The addition of calcium sulfite/sulfate enhanced utilization when slurried at 25° C. at the fly ash/lime/calcium salt weight ratio of 16:1:14. The effect was dramatic when calcium sulfate was used.

Experiments with clays as an alternate source of silica proved that they also may be effective in the formation of calcium silicate hydrate. Montmorillonite performed as well as fly ash at a loading of 2. At high loading it was only slightly less effective. The use of clays in the place of fly ash offers the advantage of uncontaminated by-product fly ash.

Also from the above presented results it becomes clear that fly ash TAMO (total alkaline metal oxide content) has no decisive effect on the removal of SO₂ in the spray dryer when slurried alone, the recycle of spray dryer/bag filter off-product provides the opportunity for unspent Ca(OH)₂ to be reacted with fly ash in addition to providing the unspent Ca(OH)₂ with another chance to see and react with SO₂, enhancing the reaction of Ca(OH)₂ with fly ash in the recycle system should improve the overall performance of the spray dryer/bag system.

The advantage of highly reactive solids may be fully utilized in a commercial unit after optimization of the recycle conditions. Presently it is commercial practice to design the recycle tank for about 2 hours residence time. At ambient temperature or adiabatic conditions the effect of heat evolving when warm spray dryer solids are added is negligible. As shown by the results of this study, it would be preferred to increase the size of recycle tank up to 6 hours, preferably even 8 hours. The temperature of the slurry should preferably not be lower than 65° C. to take advantage of a steep change in a reactivity of solids. One option to provide the necessary amount of heat would be to add fly ash directly to the CaO slaker. The recycle tank should be designed carefully to avoid problems with plugging from reaction products and excessive deposit built-up on the walls.

It is possible that the spray dryer could be operated with wider approach to the saturation temperature because more reactive solids would be sprayed. Additional increase of Ca(OH)₂ reactivity in the fly ash-Ca(OH)₂ system might be possible with deliquescent salt additives. Sand bed studies showed the increase of Ca(OH)₂ reactivity when calcium and sodium salts were used. Sodium and calcium salts are widely used as cement retarders and by analogy they should work well also in the fly ash system.

The lab scale experiments also indicate that dry injection of solids into the duct should be accompanied by humidification of the gas. High humidification could be used in installations with ElectroStatic Precipitators (ESP). One option is that the dry solids would be produced outside the system and then injected into the duct and later humidified. Second is that the reacted slurry of fly ash and lime would be introduced into spray dryer operating at wide approach to the saturation. This spray dryer would operate as dryer and absorption of SO₂ would be of secondary concern. Spray dryer-dry solids would be then passed into the duct where they would contact humidified gas. Dry injection in the system with ESP requires additional laboratory studies of the rates of reaction at short times.

The idea of producing the reactive solids could be also retrofitted into existing desulfurization installations. It should be feasible for example to collect the product solids from Limestone Injection Multistage Boiler (LIMB), slurry them at favorable conditions and redistribute. The typical product of LIMB is CaO, CaSO₄, and fly ash at the ratio of 3:1:2, which could be simulated in sand bed reactor.

Still another possibility would be Slurry Atomization into Multistage Burner (SAMB) which would consist of spray drying of lime/fly ash slurry at burner temperatures and collecting the dry solids in either ESP or bag filter after additional humidification in the duct.

EXAMPLE II: THE EFFECT OF NaOH ADDITION TO THE SLURRY

It has also been observed that the addition of sodium hydroxide to the slurry serves to potentiate the slurry's sulfur-adsorbing capability, possibly due to the increased formation of calcium silicates and aluminates at more alkaline pH's. In FIG. 9, about 1 part Ca(OH)₂ was slurried at 65° C. for 6 hours with 4 parts fly ash and 4 parts CaSO₃, but without the addition of NaOH. SO₂ removal (moles SO₂ /100 moles Ca(OH)₂) ranged from about 20, when solids were reacted with gas at about 65° C., to about 10, when reacted with gas at about 92° C.

When 0.03M NaOH was added to a level of 10 mole %, the SO₂ removal ranged from about 22, when reacted with gas at 65° C., to about 10, when reacted with gas at about 105°. When 0.08M NaOH was added after the slurry was slurried for 6 hours, and then dried an additional 30 hours in the presence of the added NaOH, the SO₂ removal increased to a range of about 58, when reacted with gas at 65° C., to about 30, when reacted with gas at about 92° C., and to about 22, when reacted with gas at about 125° C. When this concentration of NaOH was slurried for only 4 hours, the SO₂ removal observed ranged from about 64, at 65° C., to about 20, at 92° C. A longer slurrying time prior to NaOH addition gave similar results. The addition of 0.25M NaOH demonstrated only slight improvement over control. However, in all cases, it was observed that the addition of NaOH to the slurry improved SO₂ removal efficiency.

SORBENTS PREPARED AT TEMPERATURES BETWEEN 100° and 200° C.

A generalized flowsheet including the major embodiments of processes according to this aspect of the invention is shown in FIG. 10. The sorbent is prepared by mixing water, calcium source, and the silica source in a pressurized hydrator/mixer at elevated temperature. A sufficient quantity of water (greater than 60 wt. %) is added to maintain the mixture in a slurry form, the water acting as a medium for reactions between lime and silica source to form calcium silicate hydrates. As with temperatures below 100°, at pressure hydration temperatures above 100° and below 200° C., virtually any composition which includes a source of calcium alkali [CaO or Ca(OH)₂ ] may be employed in the practice of the present invention. For example, calcium alkali in the form of lime, slaked lime, hydrated lime, calcitic lime, dolomitic lime, carbide lime, calcium hydroxide or calcium oxide may be employed. For economic reasons, due to its lower cost, a preferred embodiment of the present invention employs lime or slaked lime.

Similarly, virtually any composition which includes a calcium reactive silica may be employed, wherein a calcium-reactive silica is defined as a source of silica which is readily soluble in alkaline solutions. Such compositions include, but are not limited to, fly ash, diatomaceous earth, clay, bentonite, montmorillonite, or silicic acid. Again, for economic reasons, one would generally prefer to employ fly ash in that fly ash is a natural by-product of coal combustion and is therefore readily available at coal burning power plants. Moreover, fly ash may be included in the slurry in the form of spent solids recycled. When fly ash and lime are the raw materials, the weight ratio is preferably in the range of 1:1 to 3:1. when clay, diatomaceous earth or recycle solids is used as the silica source and lime is the calcium source, the silica to calcium ratio is preferably less than 2:1. The current invention enables the use of relatively low fly ash/lime or silica/calcium ratio to reduce the raw material consumption rate, the size of the hydrator and the energy requirement.

Another step of the most general process of the present invention involves heating the slurry to an optimum temperature range or thermal window and maintain the slurry temperature within the thermal window for a period of time. Since the optimum temperature range is higher than 100° C., the pressure inside the hydrator/mixer is necessarily kept above atmospheric pressure. The preferred temperature range of this thermal window varies with the type of silica used, the ratio of calcium/silica mixed and the mixing time employed. In the case of a typical coal-fired power plant using lime and fly ash (including fly ash in recycled solids from the particulate collector), the temperature range of the preferred thermal window will typically be on the order of about 110 to 180° C. and a corresponding pressure range of about 20 to 100 psia. An even more preferred temperature window ranges from between about 140° and 160° (3 to 7 psia), wherein a particularly active sorbent is produced. The fly ash to lime weight ratio charged to the hydrator is preferably controlled in the range of 1:1 to 3:1.

However, broadly speaking, advantages may be realized with virtually any of the aforementioned calcium and silica sources, wherein the sorbent activation is conducted at between about 100° and 200° C. (1 to 15 psia). Controlling the temperature and pressure to within this thermal window is believed to result in the production of a highly sulfur-reactive species of calcium silicate hydrate.

Another advantage of the above described thermal window is the reduced reaction time required to achieve optimal reactivity. For example, at slurrying temperatures below 100° C., optimal reactivity is achieved in 6 to 12 hours or more. However, at temperatures above 100° C., optimal reaction times are reduced to below 4 hours and, at the most preferred range of 140° to 160° C., the optimal reaction time is reduced to less than about 1 hours. The significant reduction in fly ash to lime ratio and reaction time results in considerable savings in capital cost (smaller hydrator, conveyor, and storage tanks) and operating cost (lower energy and raw material consumption) makes the current invention an economical and technically desirable process for application to large coal-fired power plants.

After the slurry has been adequately mixed and heated, a drying means is preferable included to dewater and dry the slurry into discrete, fine powders. In this embodiment, the drying means can be employed in the form of a fluidized bed, flash dryer, spray dryer or other means known in the art. Oven drying followed by crushing and screening can also accomplish the purpose. The drying means may also employ a dewatering device, for example a vacuum or centrifuge device, before the primary drying means.

The dry silicate hydrates are used as the sorbent for dry flue gas desulfurization process. The dry flue gas desulfurization process includes a means for humidifying the flue gas, means for admixing the flue gas with the solid component to provide a gas/solid suspension, and means for separating the solid product from the gas/solid suspension before the flue gas is directed to a stack as shown in FIG. 10.

The most convenient means of achieving a humidification of gas will be through the utilization of water, for example, mixed with the gas with a spray of fine water droplets. The gas is preferably conditioned to a relative humidity of between about 20 to 90%. Additionally, the temperature of the hot flue gas (generally between about 150 and 300° C.) is preferably conditioned to between about 50 and 100° C.

The dry calcium silicate hydrates can be transported into the flue gas stream by conventional dry solids injection means such as pneumatic or mechanical conveyor. The means for admixing the flue gas and the injected sorbent can be a section of ductwork, a gas/solid contractor such as a moving bed or a circulating fluidized bed, or the like.

It is commonly known in the art that low flue gas temperature and high humidity increase sulfur dioxide solubility and reactivity with sorbent. The gas/solid admixing means provides intimate sulfur dioxide/sorbent contact and lengthens the contact time which would enhance mass transfer and overall sulfur dioxide removal efficiency.

Following the gas/solid admixing, the sorbent used and sulfur dioxide absorbed should be separated from the gas stream. The separating means including baghouse, electrostatic precipitator, mechanical impactor or cyclone. Additional sulfur dioxide removal is obtained if a long solids residence time device such as a baghouse is used as the particulate collector. The solids collected can be recycled to the hydrator as the silica source to produce more reactive calcium silicate hydrates for further sulfur dioxide removal.

EXAMPLE III: SORBENTS PREPARED AT ELEVATED TEMPERATURES

Various experiments have been performed in support of this aspect of the invention. Calcium silicate hydrates were prepared in a pressure reactor (300 ml) by mixing lime and siliceous material at elevated temperature. The pressure reactor was equipped with a stirrer and an electrical heater controlled by a thermocouple inside the reactor. After reactants (lime and siliceous material) were placed in the reactor, the vessel was sealed and heated electrically. Pressurized water was injected into the reactor when the temperature reached the experimental value. The reactants and water were vigorously stirred for a designated time period. After completion of each lo run, the reactor vessel was opened and the product was removed and dried.

The reactivity of the calcium silicate hydrates produced was evaluated in an apparatus similar to that shown in FIG. 2 and discussed above. Briefly, a glass reactor (40 mm in diameter, 120 mm in height) was packed with the dried calcium silicate hydrates mixed with 40 g of 100 mesh, silica sand to prevent channelling. The reactor was immersed in a water bath thermostated to within approximately 0.1° C. Simulated flue gas was obtained by mixing nitrogen and sulfur dioxide (500 ppm) from gas cylinders. The flow of gas was monitored using rotameters. Water was metered by a syring pump, evaporated, and injected into dry gas to control the humidity at 60%. The SO₂ concentration coming in and going out of the glass reactor was measured with a pulsed fluorescent SO₂ analyzer (ThermoElectron Model 40). Exposure time of the packed bed to the gas was 1 hour. The reactivity of the calcium silicate hydrates tested was described by conversion of lime [Ca(OH)₂ ] added to the reactor. Conversion of Ca(OH)₂ is the number of moles of SO₂ reacted per mole of Ca(OH)₂ used, multiplied by 100 percent.

The results of the first set of experiments are presented in FIG. 11 as a plot of product reactivity vs. preparation time (employed for heating the lime and fly ash slurry). The upper curve represents the reactivity of calcium silicate hydrates prepared under pressure at 150° C. The lower curve represents reactivity of product prepared in an open beaker at atmospheric pressure and heated to 90° C. It is apparent that the pressure hydration resulted in a much more reactive product than atmospheric hydration. Since the upper curve leveled off after about 4 hours, it means that only 4 hours or less preparation time is required to achieve the maximum effect of pressure hydration.

The effect of temperature of pressure hydration was investigated during the second set of experiments. As shown in FIG. 12, the reactivity of the calcium silicate hydrates produced under pressure demonstrated surprisingly good reactivities when prepared at temperatures between 100° and 200° C., and peaked at temperature about 140 and about 160° C., evidencing the thermal window effect. The data shown in FIG. 12 indicated that when preparation temperature exceeded 160° C. the reactivity dropped precipitously, with temperatures above 200° C. being much less reactive.

Surface area of the calcium silicate hydrates was measured during a third set of experiments. FIG. 13 represents the correlation of reactivity with B.E.T. surface area. This figure shows that, in general, the reactivity correlated quite well with the B.E.T. surface area and that it increased with the increasing surface area of the product. The three data points expressed as open circles represent reactivity of calcium silicate hydrates produced at temperatures below the thermal window of 140 to 160° C. It is apparent that the surface are of those products had not been fully developed, probably resulting in a shortage of reaction sites and, hence, low reactivities. On the other hand, the two open squares on FIG. 13 represent reactivities of calcium silicate hydrates produced at temperatures higher than the thermal window of 140 to 160° C. The reactivities of those two data points do not fit the correlation curve with B.E.T. surface area as shown in FIG. 13, although moderate to high surface area was obtained, the reactivity was extremely low.

To further investigate the temperature effects on product reactivity, the crystal morphology was examined by scanning electron microscope. It was found that the calcium silicate hydrates produced within the thermal window are gel-like, amorphous particles. However, needle-like, well-defined crystals were formed when the temperature is above the optimal temperature. Apparently, the high temperature caused solid phase transition and a different crystal was formed. This new crystal, although still possessed moderately large surface area, was not nearly as reactive toward sulfur dioxide. It is possible that this new crystal has a composition, e.g., containing very little hydrated water molecule, that is unfavorable toward sulfur dioxide absorption. It is also possible that the high temperature caused structural property changes and resulted in low reactivity. Therefore, the combination of degree of crystallization-transition of the final product's composition and the clay-like structure's temperature sensitivity could account for thermal window effect.

Further experimentation was conducted in order to demonstrate the surprising reduction in treatment time provided by the use of elevated temperatures. In particular, experiments were conducted wherein the incubation times required to approximately double the reactivity of the sorbent were determined. From the results shown in FIG. 14, it is apparent that sorbents produced the reactivity of temperatures above about 100° C. and below about 200° C. are at least doubled in less than 6 hours. Moreover, in the more preferred range of about 120° to about 180° C., reactivities are doubled in less than about 2 hours. Surprisingly, at the most preferred temperature range of about 140° to about 160° C., sorbent reactivities were doubled in less than 1 hour. 

What is claimed is:
 1. An apparatus for treating a gas stream to remove acid components therefrom, the apparatus comprising:a) activating means for activating an acid gas-absorbing component, which component includes a calcium silicate formed from a calcium alkali and calcium-reactive silica or alumina, the activating means including means for elevating the temperature of the component to above ambient prior to contacting said component with a gas stream for a period of time effective to promote activation of acid gas absorbing component; b) admixing means, positioned in operable communication with the activating means, to receive activated absorbing component from the activating means, for admixing the activated absorbing component to treat the gas stream by absorbing acid components therefrom; and c) separating means, in operable connection with the admixing means, for separating treated gas from the absorbing component.
 2. The apparatus of claim 1, wherein the activating means comprises means for slurrying the calcium alkali and calcium-reactive silica or alumina in an aqueous suspension.
 3. The apparatus of claim 2, wherein the activating means comprises a slurry tank.
 4. The apparatus of claim 1, wherein the activating means comprises means for subjecting the calcium alkali and calcium-reactive silica or alumina to an elevated pressure.
 5. The apparatus of claim 4, wherein the activating means includes a pressure hydrator.
 6. The apparatus of claim 2, wherein the admixing means comprise means for admixing the gas with the activated absorbing component to provide a gas liquid suspension.
 7. The apparatus of claim 6, wherein the admixing and separating means include means for drying the gas liquid suspension to provide a gas/solid suspension, and means for separating the gas/solid suspension to provide a gaseous component and a solid component.
 8. The apparatus of claim 7 further comprising means for recycling a portion of the solid component to the slurry means.
 9. The apparatus of claim 1 wherein the admixing means includes a spray dryer.
 10. The apparatus of claim 1, wherein the separating means includes a bag filter.
 11. The apparatus of claim 1 wherein the separating means includes an electrostatic precipitator or cyclone.
 12. An apparatus for preparing an acid gas sorbent for use in connection with a coal-fired power plant to reduce the amount of acid gas components in gaseous emissions therefrom, the apparatus comprising a pressure hydrator or temperature-regulated slurry tank, wherein the pressure hydrator or temperature-regulated slurry tank is in operable connection to receive calcium alkali and calcium reactive silica or alumina from an external calcium alkali and calcium-reactive silica or alumina source and deliver activated sorbent to a mixing chamber, the pressure hydrator or temperature-regulated slurry tank for activating an acid gas absorbing component.
 13. The apparatus of claim 12 further comprising a separator in the form of a bag filter, electrostatic percipitator or cyclone, positioned in communication with the mixing chamber so as to receive spent sorbent and treated gas therefrom, for separating spent sorbent from the treated gas.
 14. The apparatus of claim 12, further comprising a dewatering device connected in communication with the pressure hydrator or temperature-regulated slurry tank to receive activated acid gas absorbing component therefrom, the dewatering device for removing water from the acid gas absorbing component.
 15. The apparatus of claim 13, further comprising a venting stack, connected in operable communication with the separator, to receive treated gas therefrom and vent the treated gas.
 16. The apparatus of claim 12, further comprising a dry injection device, positioned in operable communication with the pressure hydrator or temperature regulated slurry tank for receiving sorbent therefrom and admixing the sorbent with gas to be treated.
 17. The apparatus of claim 12, further comprising a fluidized bed, flash dryer or spray dryer positioned in operable communication with the mixing chamber.
 18. The apparatus of claim 12, further comprising a gas humidifier positioned in communication with a gas source of gas to be treated and the mixing chamber for humidifying the gas to be treated.
 19. The apparatus of claim 12, further comprising a baghouse or electrostatic precipitator positioned in communication with the mixing chamber.
 20. The apparatus of claim 12, wherein the calcium-reactive silica or alumina source comprises a fly-ash source.
 21. The apparatus of claim 12, further comprising means, connected to said pressure hydrator or temperature-regulated slurry tank, for admixing activated sorbent with dry solids to provide a free-flowing, semi-dry sorbent.
 22. An apparatus for reducing the level of acid gas components in a gas stream, the apparatus comprising:a) a source of calcium alkali and calcium-reactive silica or alumina; b) an activation device connected in operable communication with said source o receive calcium alkali and calcium-reactive silica or alumina therefrom, for activating the calcium alkali and calcium-reactive silica or alumina to produce an acid gas absorbing component that includes calcium silicate; c) a mixer, connected in operable communication with said activation device, the mixer adapted to bring the calcium silicate absorbing component into contact with a gas stream in a manner effective to treat gas to reduce the level of one or more acid components therein; and d) a separator, connected in operable communication with said mixer, that separates the absorbing component from treated gas stream.
 23. The apparatus of claim 22, wherein the activation device comprises a temperature-regulated slurry tank or pressure hydrator.
 24. The apparatus of claim 22, wherein the mixer comprises a rotary or fluid atomizer.
 25. The apparatus of claim 22, wherein the separator comprises a spray dryer or bag filter.
 26. The apparatus of claim 22, further comprising a dewatering device connected in operable communication with the mixer.
 27. The apparatus of claim 22, further comprising an atomizer connected in operable communication with the mixer.
 28. An apparatus for reducing the level of acid gas components in a gas stream, the apparatus comprising:(a) a gas/solid separator in contact with a gas stream for collecting solids that include fly ash and calcium oxide or hydroxide; (b) a temperature-controlled slurry tank connected to the gas/solid separator, the slurry tank for producing an activated sorbent; (c) admixing means for admixing solids from the separator with activated sorbent from the slurry tank, to produce free flowing solids; (d) means, connected to the admixing means or slurry tank, for injecting the free-flowing solids into the gas stream; and (e) means, connected to the slurry tank or admixing means, for conveying solids from the gas/solid separator to the slurry tank or admixing means.
 29. The apparatus of claim 28, wherein the admixing means further comprises a dewatering or drying device for partially dewatering or drying activated slurry.
 30. The apparatus of claim 28, wherein the gas/solid separator comprises an electrostatic precipitator, bag filter, or cyclone. 